Rebuilding 37mm front forks – TRAC side – Honda CX500E, CX650E – Part 02

From the first part here we left with the springs and whatnot being put onto the damper rod:

Here's how we rebuilt the TRAC side of the front suspension forks on a Honda CX500E or CX650E motorcycle.

Now we need to start putting things back on the chrome fork slider. Add the guide bush (51414-MN4-003, CMSNL):

Here's how we rebuilt the TRAC side of the front suspension forks on a Honda CX500E or CX650E motorcycle.

It should slide all the way to the bottom and rest against the top of the two bushings down there (51440-MG0-003, CMSNL).

Here's how we rebuilt the TRAC side of the front suspension forks on a Honda CX500E or CX650E motorcycle.

Next comes the backup ring:

Here's how we rebuilt the TRAC side of the front suspension forks on a Honda CX500E or CX650E motorcycle.

Make sure that the side with the lip is facing upwards, or towards the oil seal (and away from the bushing you just put on):

Here's how we rebuilt the TRAC side of the front suspension forks on a Honda CX500E or CX650E motorcycle.

Here's how we rebuilt the TRAC side of the front suspension forks on a Honda CX500E or CX650E motorcycle.

Coat the inside of the oil seal and the outside of the chrome slider lightly in the fork oil you’ll be using to assist with easing it on:

Here's how we rebuilt the TRAC side of the front suspension forks on a Honda CX500E or CX650E motorcycle.

…and put some tape over the lines at the top of the fork to help reduce the chance of damaging the seal on installation:

Here's how we rebuilt the TRAC side of the front suspension forks on a Honda CX500E or CX650E motorcycle.

Here's how we rebuilt the TRAC side of the front suspension forks on a Honda CX500E or CX650E motorcycle.

Carefully slide it down the fork tube evenly (don’t push one side down and not the other). Which way does it go on? If there’s a spring visible on one side and the other is flat, the spring side goes down (towards the oil). If there’s a spring visible from both sides, the side with the numbers on it goes up.

Here's how we rebuilt the TRAC side of the front suspension forks on a Honda CX500E or CX650E motorcycle.

Here's how we rebuilt the TRAC side of the front suspension forks on a Honda CX500E or CX650E motorcycle.

Now the lower end of your slider should look like this:

Here's how we rebuilt the TRAC side of the front suspension forks on a Honda CX500E or CX650E motorcycle.

Push the fork slider into the fork lower:

Here's how we rebuilt the TRAC side of the front suspension forks on a Honda CX500E or CX650E motorcycle.

Here's how we rebuilt the TRAC side of the front suspension forks on a Honda CX500E or CX650E motorcycle.

To drive in the new seal we take the old fork seal, put it on the slider upside down:

Here's how we rebuilt the TRAC side of the front suspension forks on a Honda CX500E or CX650E motorcycle.

…and then drive it in using a section of 40mm PVC pipe, ensuring that the pipe has been cut at as close to a right angle as possible.

That’s as far as I have gotten with this guide – more to come if/when I revisit the article.

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